Recent Developments in Abrasive Hybrid Manufacturing Processes

Ruszaj, Adam; Skoczypiec, Sebastian; Wyszyński, Dominik

doi:10.1515/mper-2017-0020

Cited by 17 publications

(12 citation statements)

References 24 publications

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“…The WEDM process extracts particles from the surface through thermal erosion [ 3 ]. In order to use WEDM, the workpiece and tool must be electrically conductive [ 4 , 5 ]. The wire acts as a cathode, and the work material acts as an anode.…”

Section: Introductionmentioning

confidence: 99%

Optimization of Wire Electric Discharge Machining (WEDM) Process Parameters for AISI 1045 Medium Carbon Steel Using Taguchi Design of Experiments

et al. 2022

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With the growth of the manufacturing industry, the demand for alloy materials with high hardness, toughness, and impact strength has increased. Since products from such alloy materials are extremely difficult to manufacture with high accuracy and reduced surface roughness using traditional machining techniques, wire electric discharge machining can be used to machine such complex parts with more precision. In this case-study-based research, machining factors such as current, pulse-on time, and voltage are studied to determine their effects on the material removal rate for AISI 1045 medium carbon steel. The Taguchi L9 orthogonal array is used in the design of experiments for optimization. Statistical techniques such as analysis of variance and signal-to-noise ratio are used to identify the control parameters that matter most in bringing about optimal results. Based on the results, the current is the most crucial control variable in this investigation. Moreover, the maximum material removal rate obtained was 0.7112 mm3/min with the obtained optimized values of current (I) = 16 A, voltage (V) = 50 V, and pulse-on time (Ton) = 100 µs.

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Section: Introductionmentioning

confidence: 99%

Optimization of Wire Electric Discharge Machining (WEDM) Process Parameters for AISI 1045 Medium Carbon Steel Using Taguchi Design of Experiments

et al. 2022

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“…In recent years, the rapidly rising demand for materials with special characteristics in such advanced industrial applications as aerospace and surgical instruments, has led to the development of new materials. However, these materials are mostly difficult-to-cut using more conventional manufacturing processes [1,2,3,4,5] and this pushes manufacturers to explore new machining processes which maintain or even improve precision but at reasonable cost.…”

Section: Introductionmentioning

confidence: 99%

Advanced Electric Discharge Machining of Stainless Steels: Assessment of the State of the Art, Gaps and Future Prospect

et al. 2019

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Electric discharge machining (EDM) is a material removal process that is especially useful for difficult-to-cut materials with complex shapes and is widely used in aerospace, automotive, surgical tools among other fields. EDM is one of the most efficient manufacturing processes and is used to achieve highly accurate production. It is a non-contact thermal energy process used to machine electrically conductive components irrespective of the material’s mechanical properties. Studies related to the EDM have shown that the process performance can be considerably improved by properly selecting the process material and operating parameters. This paper reviews research studies on the application of EDM to different grades of stainless steel materials and describes experimental and theoretical studies of EDM that have attempted to improve the process performance, by considering material removal rate, surface quality and tool wear rate, amongst others. In addition, this paper examines evaluation models and techniques used to determine the EDM process conditions. This review also presents a discussion on developments in EDM and outlines the likely trend for future research.

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“…10c. This is not uncommon when machining CFRP using either a conventional cutting edge or abrasive grits and is attributed to the abrasive properties of carbon fibre reinforcement as observed by Ruszaj et al [17]. Additionally, matrix resin melt and cut fibres were observed on abrasive surfaces; see Fig.…”

Section: Post-machining Tool Examinationmentioning

confidence: 68%

Performance of a new hybrid cutting-abrasive tool for the machining of fibre reinforced polymer composites

Shyha

Huo

Hesamikojidi

et al. 2020

Int J Adv Manuf Technol

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A new hybrid cutting-abrasive machining tool (turn-grind) is detailed for high-quality machining of fibre reinforced polymer (FRP) composites, comprising single point carbide inserts electroplated with multi-layers of diamond abrasives 120 μm grain size, to form an abrasive region adjacent to an abrasive-free cutting edge. Experimental data are presented for turning tubes of CFRP and GFRP. The surface quality of workpieces after machining was evaluated through surface roughness measurements and SEM imaging. Cutting-only caused more defects such as delamination and fibre to pull out. Compared with cutting-only, contact and non-contact measurement of surface roughness (Ra) in both axial and radial directions showed an increase for CFRP and GFRP with roundness error reduced to 50%. No significant increase in cutting force was observed.

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Recent Developments in Abrasive Hybrid Manufacturing Processes

Cited by 17 publications

References 24 publications

Optimization of Wire Electric Discharge Machining (WEDM) Process Parameters for AISI 1045 Medium Carbon Steel Using Taguchi Design of Experiments

Optimization of Wire Electric Discharge Machining (WEDM) Process Parameters for AISI 1045 Medium Carbon Steel Using Taguchi Design of Experiments

Advanced Electric Discharge Machining of Stainless Steels: Assessment of the State of the Art, Gaps and Future Prospect

Performance of a new hybrid cutting-abrasive tool for the machining of fibre reinforced polymer composites

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